Web Tech AutoWeigh Masterweigh Novus User manual

Installation and Operation Manual
Web Tech AutoWeigh
11 Electronics St
Eight Mile Plains, QLD, 4113
Ph: 1800 777 906
Fax: [phone]
E-mail: [e-mail]

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i
NOVUS INSTALLATION AND OPERATION MANUAL
Contents
Contents ................................................................................................................................................ i
Revisions...............................................................................................................................................1
Introduction..........................................................................................................................................2
User Interface.....................................................................................................................................12
Setup & Calibration (Main Menu) ......................................................................................................17
1 –Setup Parameters .........................................................................................................................18
1.1 –Units of Measure.............................................................................................................18
1.2 –Belt Length......................................................................................................................18
1.3 –Scale Capacity .................................................................................................................18
1 –Setup Parameters .........................................................................................................................19
1.4 –Scale Resolution..............................................................................................................19
1.5 –Machine type ..................................................................................................................19
1.6 –Equipment ID ..................................................................................................................19
2 –System Settings.............................................................................................................................20
2.1 –Firmware Version............................................................................................................20
2.2 –Backlight..........................................................................................................................20
2.3 –Contrast...........................................................................................................................20
2 –System Settings.............................................................................................................................21
2.4 –Time ................................................................................................................................21
2.5 –Date.................................................................................................................................21
3 –Belt Length Calibration .................................................................................................................22
3.1 –Auto Pulse Count Calibration..........................................................................................23
3.2 –Manual Pulse Entry Calibration.......................................................................................25
4 –Zero Calibration ............................................................................................................................26
4.1 –Automatic Zero Calibration.............................................................................................27
4.2 –Manual Zero Calibration .................................................................................................28
5 –Span Calibration............................................................................................................................29
5.1 –Calibrated Weigh Test.....................................................................................................30
5.2 –Reference Scale Test.......................................................................................................33
5.3 –Manually Enter Span Value.............................................................................................35
6 –Auto Zero Tracking........................................................................................................................36
6.1 –AZT Control –Off.............................................................................................................38
6.2 –AZT Control –On.............................................................................................................40
7 –Null Setup .....................................................................................................................................41
8 –Filter Setup....................................................................................................................................43
9 –Current Loop Setup.......................................................................................................................46
9.1 –Input Loop.......................................................................................................................47
9.1.1 –Input Loop –Calibration Page......................................................................................48
9.1.1.1 –Input Loop –Parameter: Setpoint ............................................................................49
9.1.1.2 –Input Loop –Parameter: Inclinometer .....................................................................50

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9.1.1.3 –Input Loop –Parameter: Not Used..........................................................................51
9.2 –Output Loop....................................................................................................................52
9.2.1 –Output Loop –Calibration Page...................................................................................53
9.2.1.1 –Output Loop –Parameter: Belt Speed......................................................................54
9.2.1.2 –Output Loop –Parameter: Belt Loading ...................................................................55
9.2.1.3 –Output Loop –Parameter: Inlet Boot Refill ..............................................................56
9.2.1.4 –Output Loop –Parameter: Not Used........................................................................57
9.2.1.5 –Output Loop –Parameter: PID..................................................................................58
9.2.1.6 –Output Loop –Parameter: Rate................................................................................59
10 –Digital I/O Setup..........................................................................................................................60
10.1 –Digital Input...................................................................................................................61
10.1.1 –Pre-Programmed Digital Input Functions ..................................................................62
10.2 –Digital Output................................................................................................................63
10.2.1 –System Healthy ..........................................................................................................64
10.2.2 –Totaliser .....................................................................................................................65
10.2.3 –Digital Output 3..........................................................................................................66
10.2.4 –Digital Output 4..........................................................................................................67
11 –PID Setup ....................................................................................................................................68
11.1 –Setpoint Control............................................................................................................70
11.2 –PID Control....................................................................................................................71
11.3 –PID Parameters .............................................................................................................72
11.3.1 –PID Parameters List....................................................................................................73
11.4 –PID Tuning.....................................................................................................................74
11.5 –Volumetric Restart........................................................................................................75
11.6 –PID Monitor...................................................................................................................76
12 –Chute Control..............................................................................................................................77
12.1 –Inlet Boot Hopper .........................................................................................................79
12.1.1.1 –Inlet Boot Hopper –Zero Value ..............................................................................81
12.1.1.2 –Inlet Boot Hopper –Span Value..............................................................................82
12.1.1.3 –Inlet Boot Hopper –Sensor Type............................................................................82
12.1.2 –Inlet Boot Hopper –Load Cell Sensor ........................................................................83
12.1.2.1 –Load Cell Sensor –Output Control: Analogue ........................................................85
12.1.2.2 –Load Cell Sensor –Output Control: Linear..............................................................87
12.1.2.3 –Load Cell Sensor –Output Control: Digital .............................................................88
12.1.3 –Probe Control.............................................................................................................90
12.2 –Pre-Feed Hopper...........................................................................................................92
13 –Field Bus Setup ...........................................................................................................................95
13.1 –DeviceNet......................................................................................................................96
13.1.1 –DeviceNet LEDs ..........................................................................................................97
13.2 –Ethernet/IP & Modbus TCP...........................................................................................98
13.2.1 –Ethernet/IP & Modbus TCP LEDs .............................................................................100
13.3 –Profibus.......................................................................................................................101
13.3.1 –Profibus LEDs ...........................................................................................................102

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13.4 –RS232 ..........................................................................................................................103
13.5 Profinet ..........................................................................................................................104
13.5.1 –Profinet LEDs............................................................................................................106
14 –Speed Sensor Setup ..................................................................................................................107
15 –System Diagnostics ...................................................................................................................109
16 –Access Code Setup....................................................................................................................110
16.1 –Enabling Access Code..................................................................................................111
16.2 –Disable Access Code....................................................................................................113
17 –Save and Load Data ..................................................................................................................114
17.1 –Save Parameters .........................................................................................................115
17.2 –Load Parameters.........................................................................................................116
18 –Audit Trail .................................................................................................................................117
18.1 –View Audit Trail...........................................................................................................118
18.2 –Download Audit Trail ..................................................................................................119
Appendix A: Wiring Diagrams...............................................................................................................A
Appendix B: Board Layout Diagrams ....................................................................................................B
Appendix C: Novus Datasheets.............................................................................................................C
Appendix D: Fieldbus Communications................................................................................................D
Glossary ............................................................................................................................................- 1 -

1
NOVUS –INSTALLATION AND OPERATION MANUAL
Revisions
20/12/16 Revision A Original Weighfeeder Manual By A. Chen. Edit: B. Robinson
10/05/17 Revision 5 Edit: B. Robinson
Changed wiring diagrams.

2
NOVUS –INSTALLATION AND OPERATION MANUAL
Introduction
The Masterweigh Novus is a micro-controller based integrator to monitor beltscales or control
weighfeeders. By design it can be used in "stand alone" mode or as a slave to a PLC and other industrial
supervisory system. It is capable of maintaining and displaying the mass rate and the accumulated mass
total on the graphical LCD. Communication between the plant controller and the Masterweigh Novus is
done via Profibus, DeviceNet, Ethernet/IP, Modbus-TCP and analogue and digital inputs and outputs. The
Masterweigh Novus uses a USB slot for firmware upgrades and a SD card to extract data from the unit.

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NOVUS - INSTALLATION AND OPERATION MANUAL
Introduction –Stack
The device consists of 5 boards.
Microcontroller (MCU) board.
Power Supply (PSU) board.
Intermediate (I/O) board.
Expansion Plug-in board.
Digital Plug-in board
PSU Board
LCD
Keypad
Connector
MCU
Board
IO Board
Digital Plug in
IO Board
Expansion Plug
in IO Board

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NOVUS –INSTALLATION AND OPERATION MANUAL
Introduction –MCU Board
Reset Switch
ISP Switch
Communications
Board Connector
Clock Backup
Battery
To I/O Board
Bottom Mount
Keypad
Connector
USB Connector
SD Card
Connector
IAP Switch

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NOVUS –INSTALLATION AND OPERATION MANUAL
Introduction –PSU Board
Connector
Connector Marking
Function
AC Mains Input
A
Active
N
Neutral
E
Earth
AC-DC SMPS-1
Output Connector
(J6)
To I/O Board
AC-DC SMPS-2
Output Connector
(J7)
Earthing
Spade 1
Earthing
Spade 2
ON-OFF
Switch
AN E
AC Mains
Input
AC-DC SMPS-1
Input Connector
(J2)
AC-DC SMPS-2
Input Connector
(J3)
Fuse

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NOVUS –INSTALLATION AND OPERATION MANUAL
Introduction –IO Board
To PSU Board
Expansion Board
Connectors
CPU Board
Connectors
Digital Board
Connectors
24VDC
Output
Tacho
Input
System
Healthy
Remote
Counter
Digital
Input 1
Digital
Input 2
Digital
Input 3
Rate
Output*
Load Cell
Connector
Power Indicator LEDs
COM
N/O COM N/O + SCN - + SCN - + SCN
-
+
-
SIG- GND
EX+
SCN
SIG+ SIG- SCN
EX+
EX-
+ SCN -
J1
J2
J3
J4
J5
J6
J7
J8
J9

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NOVUS –INSTALLATION AND OPERATION MANUAL
Introduction –IO Board
Connector
Connector Marking
Function
24VDC Output (J1)
+
+24VDC
–
Ground
Tacho Input (J2)
SIG-
Speed Sensor (Tacho) Signal
GND
Ground
EX+
(Tacho) Excitation voltage +5~10V
SCN
Shield
System Healthy (J3)
COM
Common
N/O
Normally Open
Remote Counter (J4)
COM
Common
N/O
Normally Open
Digital Input - 1 (J5)
+
Digital Input 1 +
SCN
Shield
–
Digital Input 1 –
Digital Input - 2 (J6)
+
Digital Input 2 +
SCN
Shield
–
Digital Input 2 –
Digital Input - 3 (J7)
+
Digital Input 3 +
SCN
Shield
–
Digital Input 3 –
Rate Output* (J8)
+
Rate Output
SCN
Ground
–
Rate Return
Load Cell (J9)
SIG+
Load cell Signal +
SIG–
Load cell Signal –
SCN
Shield
EX+
Load cell Excitation +
EX–
Load cell Excitation –
Note:
All current loop outputs are internally powered by Masterweigh Novus

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NOVUS –INSTALLATION AND OPERATION MANUAL
Introduction –Expansion Plug in Board
SIG+
SIG-
SCN
EX+
EX-
Current Loop
Output 4*
NC
NC
Current Loop
Input 3
Pre-Feed Load Cell
Inlet Boot Load Cell
Current Loop
Input 2
Remote
Set Point
PID Output*
Current Loop
Output 3*
J13
J16
J17
J14
J15
J17
J13
J14
J15
J16
SIG+ SIG- SCN EX+ EX-
+ - GND
+ - GND
+ - GND
+ - GND
+
-
GND
+
-
GND

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NOVUS –INSTALLATION AND OPERATION MANUAL
Introduction –Expansion Plug in Board
Connector
Connector marking
in schematic
Function
Current Loop Output –3* (J13)
+
Current Loop Output +
–
Current Loop Output –
GND
Ground
Current Loop Output –4* (J13)
+
Current Loop Output +
–
Current Loop Output –
GND
Ground
PID output
Current Loop Output –2* (J14)
PID +
PID Output Signal +
PID –
PID Output Signal –
GND
Ground
Remote Setpoint
Current Loop Input - 1 (J15)
+
Setpoint Input Signal +
–
Setpoint Input Signal –
GND
Ground
Current Loop Input - 2 (J16)
+
Current Loop Input +
–
Current Loop Input –
GND
Ground
Current Loop Input - 3 (J16)
+
Current Loop Input +
–
Current Loop Input –
GND
Ground
Inlet Boot
Load Cell Input –1 (J17)
SIG +
Load cell Signal +
SIG –
Load cell Signal –
SCN
Shield
EX +
Load cell Excitation +
EX –
Load cell Excitation –
Pre-Feed
Load Cell Input - 2 (J17)
SIG +
Load cell Signal +
SIG –
Load cell Signal –
SCN
Shield
EX +
Load cell Excitation +
EX –
Load cell Excitation –
Note:
All current loop outputs are internally powered by Masterweigh Novus

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NOVUS –INSTALLATION AND OPERATION MANUAL
Introduction –Digital Plug in Board
J11
Digital
Input 4
J10
Digital
Output 3
J12
24VDC
Output
24VDC
Output
J12
Digital
Inputs 5
J11
Digital
Output 4
J10
N/O COM N/C
N/O
COM
N/C
+
SCN
-
+
-
+
-
+ SCN -

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NOVUS –INSTALLATION AND OPERATION MANUAL
Introduction –Digital Plug in Board
Connector
Connector Marking
Function
Digital Output –3 (J10)
N/O
Normally Open
COM
Common
N/C
Normally Close
Digital Output 4 –(J10)
N/O
Normally Open
COM
Common
N/C
Normally Close
Digital Input 4 –(J11)
+
Digital Input 4 +
SCN
Shield
-
Digital Input 4 –
Digital Input 5 –(J11)
+
Digital Input 5 +
SCN
Shield
-
Digital Input 5 –
Aux. 24VDC Output (J12)
+
+24VDC
–
GND
Aux. 24VDC Output (J12)
+
+24VDC
–
GND

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NOVUS –INSTALLATION AND OPERATION MANUAL
User Interface
The Masterweigh Novus user interface utilizes a tier folder type structure to manoeuver through each
section. There is a main screen (HOME) which will display the essential information for the user such as
mass rate, mass total, setpoint, control output, belt speed and some digital signals. The HOME screen is
also the default screen when Masterweigh Novus is initially powered up. The values on the HOME screen
can only be viewed, they cannot be changed.
Changing settings or calibration can be done via the tiered menu structure under Setup and Calibration
(Setup & Cal). Masterweigh Novus has implemented a ‘sketch-pad’like system where changes performed
to its settings and configurations will be written to a temporary location and will not be permanent until
the user confirms the changes prior to returning to the HOME screen. If the user chooses to discard the
changes prior to returning to main screen, then all the new changes will be lost and the unit will perform
exactly as before.
The menu structure is designed using a tier sub-menu structure which also utilizes the ‘sketch-pad’
system. There are instances where there will be a sub-menu within a menu; if the user does not save the
changes within the sub-menu and all subsequent higher tiered menus then the changes will be discarded.
Changing values in the Masterweigh Novus requires the cursor to be on the variable which requires the
change. To initiate the change, the user will have to press ENTER on the keypad which will remove the
cursor; under this mode the user may be required to enter numbers or toggle through the pre-
programmed options. Once the desired feature is entered or selected, the user will need to press the
ENTER key again to re-engage the cursor. When the cursor is not present, the user will not be able to
manoeuver between variables. The user must re-engage the cursor to navigate between two different
variables.
Tier 1
Tier 2
Tier 3
Tier 4
Masterweigh Novus Tiered Menu Structure
Home
ENTER
ENTER
ENTER
ENTER
SAVE*
Final
Confirmation
SAVE
SAVE
SAVE
HOME
ABORT*
ABORT
ABORT
ABORT
ABORT
SAVE: Exit via SAVE will store all changes to variables form the current and lower tiers into a temporary location. Any references to
lower tier’s variables with in the current tier will be to the changed values.
SAVE*: If the SAVE key is used to exit the Final Confirmation screen all changes will be saved to permanent memory.
ABORT: Exit via ABORT will discard all changes to variables from the current and lower tiers and revert them to previous values. Any
references to lower tier’s variables with in the current tier will be reverted to previous values.
ABORT*: If the ABORT key is used to exit the Final Confirmation screen all changes made will be discarded.

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NOVUS –INSTALLATION AND OPERATION MANUAL
User Interface
Novus Keypad
Numeric Keys
Function Keys

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NOVUS –INSTALLATION AND OPERATION MANUAL
User Interface
Function Keys
Save Key:
The function of the SAVE key
varies depending on each
screen. These functions are
displayed on the bottom row
of each screen. Typically the
SAVE key is used to SAVE a
changed variable and proceed
to the next page or return to
the main menu.
Abort Key:
Similarly the ABORT key’s function
differ on each screen, their
functions are displayed on the
bottom left of each screen.
Generally the ABORT key is used to
discard a changed variable and
return to the previous page or the
main menu. The ABORT key will also
allow the user to return to the
HOME screen from any of the
Setup & Calibration pages.
ENTER Key:
The ENTER key has several functions. As per the
other keys, the ENTER key’s function will be
displayed at the bottom of the screen. Its main
function is to select options or variables.
Depending on the selected option of variable,
the ENTER key will either enter the menu or
engage an editable mode where the user can
change the variable by using the numerical
keypad or left and right arrow keys. The ENTER
key can also be used to start and stop
calibrations under specific menus.
Home & Menu Keys:
The HOME and MENU keys have more specific
functions.

The MENU key will be used on the
HOME screen to access the menu
structure, Setup and Calibration.

Similarly when the user is in the menu
structure, using the HOME key will
return to the HOME screen. When the
user is in any menu or sub-menu and
requires to quickly return to the
HOME screen, using the HOME key
will discard any current process and
try to return to HOME screen. If any
other changes have been performed,
a confirmation screen will prompt the
user prior to returning to HOME
screen.
Arrow Keys:
The arrow keys allow the user to manoeuver the on-
screen cursor up and down to the desired function;
while on some variables there are pre-programmed
parameters which can be toggled using the left and right
arrow keys.

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NOVUS –INSTALLATION AND OPERATION MANUAL
User Interface
Keypad
KEY/S
FUNCTION
Numerical Keys (0-9)
Entering numerical values
Selecting Options
Decimal Point (.)
Entering numerical values
Clear (C)
Clearing entered data
Reset mass total
Arrow Keys

Moving the cursor (highlighted line)
Toggle through pre-programmed options/values
SAVE
Confirmed and save any entered/changed data and return to previous screen
ABORT
Discard any entered/changed data and return to previous screen
HOME
Return to the HOME screen
MENU
Access the Setup @ Cal page (menu page)
ENTER
Start and stop calibrations
Novus Overlay –Keypad & Screen